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**vishnups17** · 02-21-2011, 11:20 PM

Hey we are also thinking to rebuild my friends P150,but he dont want to "rebore" the cylinder head as we heard that rebored engine do not have much life.
(Pardon me i dont know about the rebuilding procedure,)actually we want the bike exactly with a new engine.So what are the things we want to change?
New block piston
New cylinder kit,new valves..then what are the other things to change?
Please help brothers

**psr** · 02-21-2011, 11:28 PM

Originally posted by vishnups17 View Post

Hey we are also thinking to rebuild my friends P150,but he dont want to "rebore" the cylinder head as we heard that rebored engine do not have much life.
(Pardon me i dont know about the rebuilding procedure,)actually we want the bike exactly with a new engine.So what are the things we want to change?
New block piston
New cylinder kit,new valves..then what are the other things to change?
Please help brothers

If you are not thinking of re-boring and want to remain stock, then you need to change the Bore and Piston with rings as a set. This will cost you approximately Rs.2,000/- for material. i am assuming that your crankshaft,it's bearings, con rod big end bearings are all in good condition.
No need to change the top head portion with Valves...valves resetting after polishing may be required,along with stem seals..approximate cost Rs.300/-

**princesirohi** · 02-22-2011, 03:00 AM

Originally posted by psr View Post

If you are not thinking of re-boring and want to remain stock, then you need to change the Bore and Piston with rings as a set. This will cost you approximately Rs.2,000/- for material. i am assuming that your crankshaft,it's bearings, con rod big end bearings are all in good condition.
No need to change the top head portion with Valves...valves resetting after polishing may be required,along with stem seals..approximate cost Rs.300/-

+ valves.....it is a better idea to replace valves also.......if we are doing such major rebuild......minor things should not be left out.

**princesirohi** · 02-25-2011, 10:56 AM

i have done 0.5 oversize bore and new piston kit, valves, stem seals etc.

now following 500kms running-in

**2stroker** · 02-26-2011, 10:29 PM

Originally posted by princesirohi View Post

i have done 0.5 oversize bore and new piston kit, valves, stem seals etc.

now following 500kms running-in

Good luck wid rebuilt.Do let us know mileage

,accceleration figures 0-60,0-100 and top speed

**reaperbabu** · 02-27-2011, 02:42 PM

Originally posted by princesirohi View Post

i have done 0.5 oversize bore and new piston kit, valves, stem seals etc.

now following 500kms running-in

No need to wait for 500 kms...vary rpm and speed for just 100.

It'll just be fine

**princesirohi** · 03-01-2011, 01:21 PM

Originally posted by 2stroker View Post

Good luck wid rebuilt.Do let us know mileage

,accceleration figures 0-60,0-100 and top speed

mileage, aceleration figures won't change much......since this is not a mod......just a simple engine rebuilt with o.5 oversize.

Originally posted by reaperbabu View Post

No need to wait for 500 kms...vary rpm and speed for just 100.

It'll just be fine

ya.....and naturally oversized bores won't be that perfect fit as a new block piston kit....so won't require a stringent running-in procedure.....but just for my satisfaction....anyway already completed 400kms...so from tommorrow or may be today evening ride back home, i will be ripping the highway for say 80 odd kms....

**amitmalve** · 11-13-2011, 02:39 PM

Hey prince, just wanted to know that after this engine work are you getting the same performance, mileage like the original one? What about reliability? I mean how many kms you have clocked after this engine work? How is your engine's current condition & oil consumption?

**rv.nikhil** · 07-02-2012, 04:21 PM

Request to fellow pulsarians, for a clear picture.

Hey ppl. .
I have been following this thread.
I own a P180 ug4, 2010. I need some help. I intend to upgrade it to p200 or 220.
Would some one lemme know the exact changes that I will be required to execute.
as I have inferred from this thread, the change to 200 is a direct fit. No alterations required for head and crank.
but I am a little confused.
Request fellow bikers for a clear cut picture of what I have to change and mod in my bike to make it a 200 or a 220, and also, which of the two are a better option.
My areas of concern are
1.the carb
2. The crank
3. Cam
4. Head n valves
5. Bore
Thanks a lot in advance for the replies guys. .
Ride on. . :-)

**princesirohi** · 07-03-2012, 11:55 AM

whoa.. this thread is still alive..

^^ a simple suggestion, plz dont go for such a mod job as it may seriously affect the reliability of the bike.

otherwise you can approach joel for such a mod, he may help you and will charge you money, you will spend more money but will get professional help.

otherwise simple thing you can do is just bore out to 1.0 mm and put oversize piston. although it will not be comparable to P200 but still you can feel the difference in power with correct carb tunning.

**Nawazish** · 02-20-2014, 11:00 PM

Re: Engine Rebuid of Pulsar 150

Hey buddy I'd like to know finally how ur rebored engine performed?

**marutinandan** · 02-26-2014, 04:56 PM

Re: Engine Rebuid of Pulsar 150

Sir, I am novice in this field,, but I have an 2003 Pulsar 150 Classic which has been opened once (i.e only piston valves and seals has been changed) now it has been emmitting white smoke, I initially planned to chnage the whole set up with that of the 180 cc, but after reading your advise I would stick to 150 CC set up. My bike has a very good pickup but then gets beaten even by a HH splendour , it seems that it should have a extra sixth gearas the top speed goes upto a mere 55-60. Sir,

1)I dnt wanna sell this bike as it has been with me in my every ups and downs!!will buy any other higher CC bike .
2)Will change the CARB with BS29 -PULSAR 180cc UG4.
3)Should I change the Piston block(in which the Piston moves up & down)?
4)Also will the engine head has to be changed?
5)The valves are to changed with 180 cc valves or should it has to be kept that those of 150CC's
6)If so , do I have to change the Cam Shaft?
7)What does over size piston means?
8)Does any one knows a GOOD MEchanic In DELHI-NCR only.

Please Advice as I love My Bike My darling,,, PLZZZ HELP ME if any other advises you have!!! and treat the matter as most urgent.

----consecutive posts auto-merged-----

Sir, I am novice in this field,, but I have an 2003 Pulsar 150 Classic which has been opened once (i.e only piston valves and seals has been changed) now it has been emmitting white smoke, I initially planned to chnage the whole set up with that of the 180 cc, but after reading your advise I would stick to 150 CC set up. My bike has a very good pickup but then gets beaten even by a HH splendour , it seems that it should have a extra sixth gearas the top speed goes upto a mere 55-60. Sir,

1)I dnt wanna sell this bike as it has been with me in my every ups and downs!!will buy any other higher CC bike .
2)Will change the CARB with BS29 -PULSAR 180cc UG4.
3)Should I change the Piston block(in which the Piston moves up & down)?
4)Also will the engine head has to be changed?
5)The valves are to changed with 180 cc valves or should it has to be kept that those of 150CC's
6)If so , do I have to change the Cam Shaft?
7)What does over size piston means?
8)Does any one knows a GOOD MEchanic In DELHI-NCR only.

Please Advice as I love My Bike My darling,,, PLZZZ HELP ME if any other advises you have!!! and treat the matter as most urgent.

**princesirohi** · 02-28-2014, 06:29 PM

Re: Engine Rebuid of Pulsar 150

Originally posted by marutinandan View Post

Sir, I am novice in this field,, but I have an 2003 Pulsar 150 Classic which has been opened once (i.e only piston valves and seals has been changed) now it has been emmitting white smoke, I initially planned to chnage the whole set up with that of the 180 cc, but after reading your advise I would stick to 150 CC set up. My bike has a very good pickup but then gets beaten even by a HH splendour , it seems that it should have a extra sixth gearas the top speed goes upto a mere 55-60. Sir,

1)I dnt wanna sell this bike as it has been with me in my every ups and downs!!will buy any other higher CC bike .
2)Will change the CARB with BS29 -PULSAR 180cc UG4.
3)Should I change the Piston block(in which the Piston moves up & down)?
4)Also will the engine head has to be changed?
5)The valves are to changed with 180 cc valves or should it has to be kept that those of 150CC's
6)If so , do I have to change the Cam Shaft?
7)What does over size piston means?
8)Does any one knows a GOOD MEchanic In DELHI-NCR only.

Please Advice as I love My Bike My darling,,, PLZZZ HELP ME if any other advises you have!!! and treat the matter as most urgent.

----consecutive posts auto-merged-----

First, i will advise you not to post same query in two different threads.

Second, you can introduce yourself in the relevant thread.

now, coming to your problem, you have not mentioned the ODO reading of your bike.

So i am assuming that it has run 40-50,000 kms.

white smoke means it is burning oil, which ideally it shouldn't. this can happen either due to block piston problem or through leaking valves.

so check the following things-

Condition of block & piston, if its too much worn out either replace or get it rebored. piston rings and oil rings will also be changed alongwith.
stem seals might be leaking, get it checked, also check valves.
for top speed problem, check your clutch plates and pressure plates.

you need to tell in detail, whether you have changed the regular wear and tear items regularly and done regular servicing and maintenance?

how is the condition of balancer gear and shaft?
chain sprocket?
timing chain?
bearings- wheels, chain sprocket, crankshaft etc?

**Ajay78** · 03-02-2014, 10:19 AM

Re: Engine Rebuid of Pulsar 150

Originally posted by marutinandan View Post

Sir, I am novice in this field,, but I have an 2003 Pulsar 150 Classic which has been opened once (i.e only piston valves and seals has been changed) now it has been emmitting white smoke, I initially planned to chnage the whole set up with that of the 180 cc, but after reading your advise I would stick to 150 CC set up. My bike has a very good pickup but then gets beaten even by a HH splendour , it seems that it should have a extra sixth gearas the top speed goes upto a mere 55-60. Sir,

1)I dnt wanna sell this bike as it has been with me in my every ups and downs!!will buy any other higher CC bike .
2)Will change the CARB with BS29 -PULSAR 180cc UG4.
3)Should I change the Piston block(in which the Piston moves up & down)?
4)Also will the engine head has to be changed?
5)The valves are to changed with 180 cc valves or should it has to be kept that those of 150CC's
6)If so , do I have to change the Cam Shaft?
7)What does over size piston means?
8)Does any one knows a GOOD MEchanic In DELHI-NCR only.

Please Advice as I love My Bike My darling,,, PLZZZ HELP ME if any other advises you have!!! and treat the matter as most urgent.

----consecutive posts auto-merged-----

Sir, I am novice in this field,, but I have an 2003 Pulsar 150 Classic which has been opened once (i.e only piston valves and seals has been changed) now it has been emmitting white smoke, I initially planned to chnage the whole set up with that of the 180 cc, but after reading your advise I would stick to 150 CC set up. My bike has a very good pickup but then gets beaten even by a HH splendour , it seems that it should have a extra sixth gearas the top speed goes upto a mere 55-60. Sir,

1)I dnt wanna sell this bike as it has been with me in my every ups and downs!!will buy any other higher CC bike .
2)Will change the CARB with BS29 -PULSAR 180cc UG4.
3)Should I change the Piston block(in which the Piston moves up & down)?
4)Also will the engine head has to be changed?
5)The valves are to changed with 180 cc valves or should it has to be kept that those of 150CC's
6)If so , do I have to change the Cam Shaft?
7)What does over size piston means?
8)Does any one knows a GOOD MEchanic In DELHI-NCR only.

Please Advice as I love My Bike My darling,,, PLZZZ HELP ME if any other advises you have!!! and treat the matter as most urgent.

You are one passionate guy for your bike man !!!! Since Mr.Sirohi has already answered all your queries, i can suggest Mahesh Motors in Ghaziabad for all your needs,

Guy is a specialist for bike's upto 500 CC, you look his profile in facebook and linkedin.

For any additional details you can PM me.

@princesirohi :- Sir Ji seems you don't remember me !!!

**nirvaana** · 03-02-2014, 11:02 AM

Re: Engine Rebuid of Pulsar 150

Originally posted by princesirohi View Post

white smoke means it is burning oil, which ideally it shouldn't. this can happen either due to block piston problem or through leaking valves.

How is leaking valve related to white smoke? While white smoke is caused by burning oil, it's reason should be busted piston rings or damaged piston/cylinder wall.

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Engine Rebuid of Pulsar 150

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